Step 2: Making a digital model

Step 3: Trial and error (Foam)

First, I took the 3D model and used Vectric's Cut 3D software http://(http://www.vectric.com/WebSite/Vectric/cut3d/c3d_index.htm) to transform the 3D file output from the Rhino software into a set of g-codes ...

Step 10: End Result

In this, my first instructible, I detail how I (with assistance) created a variation on a prop from the BBC show Torchwood. The prop in question is the "Vortex Manipulator" found on the wrist of Captain Jack Harkness. Below is a screenshot from the show of the item we are trying to replicate with some small changes. My intent with this instructible is to show how I went through the data collection, model manipulation, replica testing, mold making and pewter (yes, molten metal!) melting, pouring, and finish work.

Step 1: Getting the details

The first step involves gathering as many details about the item as possible. Through screenshots of the actual show as well as a Google image search we were able to find quite a few good images that give details on the actual device under the leather strapping. I saw that there are plenty of people out there making this replica and the majority of them appear to be plastic or resin copies. In order to be a little different I decided that a pewter metal cast would be the ideal way to stand out from these other copies. This step is rather uninteresting but crucial to the process.

I love seeing &quot;warts and all&quot; instructables where the poster tells us about their mistakes. That means I learn a lot more! Thank you very much.

Thanks for the feedback. On G+ a new maker &quot;community&quot; asked &quot;What do you make?&quot;. My response was &quot;Mistakes, mostly...&quot;. We all learn by doing, perfection is rarely (if ever) attainable, so let's show all of the steps, even the mis-steps.

It was pointed out to me recently that acetone would be a useful tool to dissolve the foam in the mold. I'm not sure how the mold would react to it but that's something I can test (I still have this mold though it has lost some of its detail).

Awesome build!

Thanks!

Props are a lot of work! Nice ible Boboprime.

Thanks!<br>I felt a little rushed, so I hope to have some nicer details, videos and pictures for future items.